Method of soldering an aluminum metal to an aluminum or another metal

ABSTRACT

A solder alloy and method for its use in soldering an aluminium metal consisting of: Al 0.5 - 4.5% by weight Cu 0.1 - 4% by weight Mg 0.005 - 0.08% by weight Ni 0 - 0.5% by weight Cr 0 - 0.5% by weight, and Zn balance.

Tlited States Patent [191 Tanaka et al.

Filed: May 25, 1971 Appl. No.2 146,625

Assignee:

Foreign Application Priority Data May 30, 1970 Japan ..45/46133 July 30, 1970 Japan ..45/66128 US. Cl ..29/504, 75/178 Int. Cl. ..B23k 31/02, 323k 35/24 Field of Search ..75/l78 AM; 29/504 References Cited UNITED STATES PATENTS 7/1935 Werley ....75/l78 AM 9/1947 Sivian ..29/503 UX 4/1961 Peterson et a] ..75/l78 AM X TENSILE STRENGTH FOREIGN PATENTS OR APPLICATIONS 362,507 12/1931 Great Britain ..75/178 AM 427,238 4/1935 Great Britain ..75/l78 AM OTHER PUBLICATIONS Soldering Manual, prepared by American Welding Society Committee on Brazing and Soldering, copyright 1959, pp. 125-126. Group 320 technical literature.

Dept. of Commerce, Bureau of Standards Circular No. 78, Solders for Aluminum, by W. S. Bates, Jan. 28, 1919.

Primary Examiner-J. Spencer Overholser Assistant Examiner-Ronald J. Shore Attorney-Stevens, Davis, Miller & Mosher [57] ABSTRACT A solder alloy and method for its use in soldering an aluminium metal consisting of:

Al 0.5 4.5% by weight Cu 0.1 4% by weight Mg 0.005 0.08% by weight Ni 0 0.5% by weight Cr 0 0.5% by weight, and

Zn balance.

5 Claims, 1 Drawing Figure 24 4s 72 96 I20 144 I68 192 216 240 TIME OF STEAM TREATMENT (Hour) PATENTEDMAY 22 1975 8 5 IEzwEw 567m;

TIME OF STEAM TREATMENT (Hour) METHOD OF SOLDERING AN ALUMINUM METAL TO AN ALUMINUM OR ANOTHER METAL BACKGROUND OF THE INVENTION This invention relates to a solder for aluminum and aluminum alloys. More particularly, this invention relates to a solder suitable for joining aluminum or an aluminum alloy and another metal such as copper, brass or iron.

As is well known, soldering of aluminum or aluminum alloys (hereinafter, simply referred to as an aluminum metal) is extremely difficult because:

1. An aluminum metal has a hard and fast oxide film covering the surface thereof.

2. Even if an aluminum metal is soldered, that is, the aluminum metal is alloyed with a solder, the soldered part suffers remarkable electrolytic corrosion, since aluminum metals have lower electrode potentials and the difference of electrode potentials between the soldered part and the aluminum matrix is great.

In order to remove or penetrate the oxide film various kinds of soldering fluxes have been developed and various means such as ultrasonic soldering, rub soldering, etc. are employed. Therefore nowadays it is quite possible to wet the surface of an aluminum metal with a solder and thus solder the metal with the same metal or another metal.

Electrolytic corrosion, however, originates in the properties of the solder and the metals to be soldered per se, and therefore it is not solved by development of soldering fluxes or soldering methods. It is no exaggeration to say that the reason why soldering of aluminum metal has been regarded as impossible resides in this corrodability of the soldered parts.

The hitherto known solders for aluminum metals are divided into two major classes- (1) tin-or cadmium-based rather low-melting point alloys containing percent zinc, and (2) zincbased rather high-melting point alloys containing aluminum and or copper.

The low-melting point solders are easy to work with, but the lack of resistance to corrosion of the soldered part is remarkable. The zinc-based high melting point solders form a good joint with aluminum metals and the soldered parts are superior in corrosion resistance to Y the soldered parts obtained with low melting solders.

However, the ZN-Al or ZN-Al-Cu alloy soldered parts are not corrosion-proof. It is merely that the corrosion proceeds more slowly than in the case of parts soldered with the Sn or Cd-based solder, because the difference in electrode potentials between Al and Zn is smaller. And if any tin, cadmium or lead exists, even in a slight amount, in the Zn-based solder, these metals precipitate at the grain boundaries and induce so-called intergranular corrosion, which results in cracking in that part. In addition, corrosion is accelerated if metals, the electrode potentials of which are very high, are heterogeneously distributed in a micro structure of the solder.

This naturally suggests that effects should be made to prepare Zn-based solders for aluminum metals containing little or no impurities. However, it has so far proved impossible to obtain zinc, the lead content of which is nil, and inclusion of small quantities of impurities is inevitable when a solder is produced, on a commercial basis.

It has been thought of to add about 0.1 percent magnesium to the Zn-based solder. Addition of magnesium impedes movement of atoms between crystals, thus stabilizing the micro structure of the alloy and preventing intergranular corrosion. Such a solder does improve corrosion resistance in the case of soldering between aluminum metals, but there is no significant difference in corrosion resistance when an aluminum metal is soldered to any other kind of metal such as copper, brass or iron. Also the addition of about 0.] percent magnesium does not give satisfactory wetting property and fluidity to the solder.

For instance, an alloy consisting of 4% Al, 0.1% Mg and Zn balance is used for soldering an aluminum plate and a copper plate.

When a soldered specimen of the above combination is left exposed to a steam-saturated atmosphere at C, intergranular corrosion takes place in 3 days and the soldered part breaks down after 15 days.

If the Mg-content is raised to 0.5 percent, similar corrosion is observed. If the Mg content is raised further, not only is the corrosion resistance not further improved but the bonding ability (or solderability) is remarkably reduced.

With this background in mind, we searched for a solder more suitable for soldering an aluminum metal and copper, brass, iron, etc. And we have found a solder which gives a good joint between aluminum metals and between an aluminum metal and the above-mentioned metals, said joint having excellent corrosion resistance, by incorporating 0.005 0.08 percent of Mg and up to 0.5 percent of Ni and/or Cr in the Zn-Cu-Al alloy solder of a certain composition.

SUMMARY OF THE INVENTION A typical solder of this invention consists of:

Al 0.5 4.5% by weight Cu' 01 4% by weight Mg 0.005 0.08% by weight and the balance being Zn and is suitable for soldering an aluminum metal and an aluminum metal or an aluminum metal and another metal such as copper, brass, iron etc.

The solder of this invention gives good joint between the above-mentioned metals, and said joint has excellent corrosion resistance.

Other compositions of the solder of this invention are:

1. Al 0.5 4.5% by weight Cu 0.1 4% by weight Mg 0.002 0.08% by weight Ni 0 0.5% by weight Cr 0- 0.5% by weight, and

Zn balance 2. Al 2 4.5% by weight Cu 0.5 3% by weight Mg 0.005 0.009% by weight Cr 0.1 0.4% by weight, and

Zn balance (3) Al 2 4.5% by weight Cu 0.5 3% by weight Mg 0.02 0.05% by weight Ni 0.15 0.5% by weight, and

Zn balance BRIEF DESCRIPTION OF THE DRAWING The accompanying drawing is a graph in which tensile strength of a bulk solder is plotted at the indicated steam-treatment time, showing superiority of corrosion resistance of the instant invention alloys over the prior art alloy. Curve A represents tensile strength of a 5% Al-Zn alloy, and curves B, C, D, E and F respectively represent these of a 4.5%Al-3%Cu-0.4%Cr- 0.009%Mg-Zn alloy, a 4%Al-3%Cu-0.4%Cr-Zn alloy, a 4.5%Al-3%Cu-0.5%Ni-0.03%Mg-Zn alloy, a 4%Al- 3%Cu-0.l%Ni-Zn alloy, a 4%Al3%Cu-0.1%Mg-Zn alloy.

DETAILED DESCRIPTION OF THE INVENTION Typical compositions of the solder of this invention have been given above. The function of each component and necessary and preferable content thereof are explained below.

Addition of at least 0.5 percent aluminum by weight improves solderability of the solder and enhances the strength of the resulting joint or soldered part and, further, prevents the brittleness caused by zinc. However, if more than 4.5 percent of Al by weight is added, brittleness is not prevented and, further, the grain of the alloy becomes coarse, which results in lowering of corrosion resistance. The aluminum content of2 4.5% by weight is preferred.

Addition of at least 0.1 percent of Cu by weight enhances the strength of the soldered part and increases affinity to copper matrix when an aluminum metal and a copper metal are soldered. However, if more than 4% of Cu is added, the melting temperature of the solder is raised and, further the soldered portion gradually shrinks or swells. The copper content of 0.5 3% by weight is preferred.

The effect of magnesium is, as mentioned above, to prevent intercrystalline movement of the atoms, to keep the micro structure homogeneous, and thus to prevent intergranular corrosion. For this purpose, at least 0.005 percent of magnesium is necessary. More than 0.08 percent of magnesium impairs fluidity and wetting property of the solder to aluminum, and does not give improvement in corrosion resistance corresponding to the increase.

The addition of chromium improves corrosion resistance and, further, increases strength of the soldered part by reducing the grain size. About 0.05 percent of chromium by weight is necessary to improve the corrosion resistance. More than 0.5 percent of chromium does not easily dissolve in zinc matrix and raises the melting point of the solder.

The chromium can be partly or wholly replaced with the same amount of nickel, the function of which is quite the same as that of chromium.

The purpose of adding chromium and/or nickel is, as with the addition of magnesium, to improve corrosion resistance. However, addition of magnesium alone does not increase the corrosion resistance of the joint between an aluminum metal and another metal such as copper, brass and iron, whereas the use of magnesium and chromium and/or nickel in combination remarkably improves corrosion resistance in the abovementioned case. This is the most remarkable feature of this invention.

The desirable ranges of magnesium and nickel or chromium are:

I. In case of chromium being added;

0.005 0.009% by weight magnesium, and 0.05

0.5% by weight chromium, preferably 0.005

0.009% by weight magnesium and 0.1 0.4% by weight chromium.

2. In case of nickel being added;

0.02 0.08% by weight magnesium and 0.05 0.5% by weight nickel, preferably 0.02 0.05% by weight magnesium and 0.15 0.5% by weight nickel. Impurities which are incidental in the ingredient metals of the solder of this invention are Sn, Pb, Cd, Fe etc. Of these, Sn, Pb and Cd promote intergranular corrosion, and therefore the proportion each of these elements must not be more than 0.01 percent. An Fe content of up to 0.1 percent of Fe is tolerable, having no deleterious effect on corrosion resistance and solderability. However, inclusion of impurities is undesirable and it is best to use materials of the highest possible purity.

If impurities such as Sn, Pb, Cd, etc. which form eutectic alloys with Zn, and have electrode potentials far different from that of Zn are included in the solder of this invention, intergranular corrosion of this solder is accelerated, and thus the Sn, Pb, Cd, etc. content should be kept within the above-mentioned limits.

For the same reason, the species of metals which can be soldered with this solder are restricted, and satisfactory results from the view point of corrosion are obtained in soldering an aluminum metal or an aluminum metal and copper, brass, iron, stainless steel, nickel or chromium.

Now the invention is illustrated by way of working examples.

Alloy samples the compositions of which are given in the following tables were prepared. For example, where the sample of Example 1 was prepared first of all, a Mg-Al mother alloy containing 10 percent by weight Mg and a Ni-Cu mother alloy containing 30 percent by weight Ni were prepared. A predetermined amount of zinc was melted in a graphite crucible, to which necessary amount of copper and the Ni-Cu mother alloy (30 percent Ni) were added, and finally necessary amounts of the Mg-Al alloy (10% Mg) and aluminum so as to produce a solder for aluminum.

First of all, corrosion tests pertaining to the solders per se were carried out, since corrosion of the joint formed by using zinc-based solders containing aluminum originates in corrosion of the solders per se. Corrodability of the solders was determined by tensile test of solder specimens before and after they were subjected to treatment with steam.

Specimens for this test were prepared as follows. A solder alloy sample was melted and cast into a brass mold from a melt of 450 C to make a specimen 8 mm in diameter and 150 mm in length. Thus obtained rod was turned so that the gage length 50 mm was a round rod having a diameter of 6.35 mm i 0.05 mm.

The steam treatment of the specimens comprised letting them stand in saturated steam at C for 10 days. Tensile tests were carried out with an Amsler universal tensile tester. It is conventionally believed that the above-mentioned steam treatment corresponds to exposure to normal conditions for 10 years.

Tensile tests of soldered joints were carried out as follows. A plurality of 20 X 50 mm strips were cut off from a 1.6 mm thick 528 (118 H 4104) corrosionresistant aluminum plate. To avoid the deleterious effect of used fluxes, we employed so-called rub soldering. A strip was picked up with pliers at one end and was heated by a gas burner flame. While the strip was being heated, a solder was rubbed in the surface of the strip to be soldered. The temperature of the aluminum strips should be higher than the melting temperature of the solder, in order that they should be soldered. The

of zinc chloride flux was applied to the parts in contact and heated to the melting temperature of a solder. A small piece of the solder was put on the contact parts, and the pieces were soldered. The remaining flux was resulting solder-plated strip was held in a vise, and an- 5 washed away with water. The test pieces, which were other strip was held by pliers so that it contacted the kept in steam at 95 100C for 5 days, 10 days and strip in the vise. The part to be joined was heated. days respectively, were checked .by visual observation when the Solder melted, Strips were P together for development of corrosion on the surface soldered. if? 3;; 5 ig a f ig ipgz g g Soldering properties of solders were evaluated by ps pre e ge er M e p 16 an CO 10 ease and completeness of soldering when strips of aluby pouring water thereupon. Excess solder that solidifled on the .oined m s as removed b a mini ma minum were JOIIlCd in the manner mentioned above. chine The gens of the g sm 8 d That is, it was checked whether or not the aluminum e g J p 6 strips were wetted by a solder rubbed on their surface termined with an Amsler universal tensile tester, before and aft r the t tm m ith steam at C for and whether or not a satisfactory oint was obtained. In

i i e w l5 evaluation of joint quality, the results of the abovethe indicated time. In each example, an average value mentioned tensile test were taken into consideration. of five test pieces is given in the table. 1

The corrosion tests on joint of aluminum and copper Conditions and results of the above-mentioned tests or steel was carried out as follows. A plurality of 30 X pertaining to solders of this invention are summarized 30 mm strips were made of a 1.6 mm thick aluminum 20 in the following table together with those on similar solplate (ls, JlS H4101), a 0.5 mm thick copper plate ders outside of the scope of this invention and the (Cup1/22JIS H3101) and a 0.5 mm thick steel plate known solders in the same category. The comparative (2s, JIS G3101). An aluminum strip was bent into an data of the table clearly prove the superiority of the solangle and put on a copper or steel strip. A small portion ders of this invention.

Tensile strength Tensile mm. 52s 52s joint(kg.) Melting Before After before range steam steam steam Strength of soldered, Example Al Cu Mg Cr Ni Zn 0). treatment treatment treatment after steam treatment Example:

1 4.5 a 0. 009 0.4 Balance. 374-395 28.0 2i.0 578 *577. 4 1 0. 00s 379-392 28.5 17.0 *520 *575. 2 0.5 0.005 379-405 21.0 14.0 575 570. 4.5 3 0.03 375-305 27.2 20.5 575 *574. 4. 1 0.02 350-392 25.0 19.5 *570 *570. 2 0.5 0.05 380-405 23.0 19.0 575 *570.

s. 0 5. 5 510 "40 (5 days after). 14.0 12.0 400 30 (5 days after).

5.0 4.0 Breakdown (1 day after).

e 3 days after. i Broken at strip.

'* Broken at joint. Partly broken at strip.

Corrosion resistance of IS/Cu(CuP H) joint Corrosion resistance o f i:IS/tron (J IS (33102) oin 10 days after 5 days after 15 days 5 days after 10 days after 15 days steam treatsteam treatafter steam steam treatsteam treatafter steam merit ment treatment merit ment treatment Soldering property Exagnple:

Do Do. Do. Do.

1 Breakdown. Breakdown Do. 2 Norm Initial stage of Advanced Normal Initial stage of Advanced Do.

corrosion. corrosion. corrosion. corrosion. 3 Initial stage of Advanced 0017- Breakdown. Initial stage of Advanced cor- Breakdown Poor, Note (1).

corrosion. rosion. corrosion. rosion. 4 Normal Initial stage of Advanced Normal Initial stage of Advanced Good.

corrosion. corrosion. corrosion. corrosion. 5 Initial stage of Advanced cor- Breakdown- Initial stage of Advanced cor Breakdowm Poor, Note (1).

corrosion. rosion. corrosion. rosion.

Rf. example:

1 Breakdown. Breakdown Good. 2 do do Poor, Note (2). 3 .do do Do.

No'rE (1).--Non-joincd parts remain because of incomplete wetting.

NOTE (2).The solder was not applied to aluminium by rubbing in Al, soldering flux was used.

The superiority of the solders of this invention in corrosion resistance is also shown in the accompanying drawing. This drawing compares corrosion resistance in term of tensile strength ofa bulk solder of this invention and that of known solders which were subjected to steam treatment. Curve A stands for a Al-Zn alloy, curve B stands for the solder of Example l of this invention, curve C stands for a 4%Al-3%Cu-0.4%Cr-Zn alloys, curve D stands for the solder of Example 4 of this invention, curve B stands for a 4%Al-3%Cu- 0.1%Ni-Zn alloy and curve F stands for a 4%Al-3%Cu- 0.1%Mg-Zn alloy. This graph shows that the solder of this invention is superior in corrosion resistance.

We claim:

1. In a method for soldering aluminum or aluminum alloys, the improvement which comprises using as the alloy, a solder alloy consisting of:

A1 0.5 4.5% by weight Cu 0.1 4% by weight Mg 0.005 0.08% by weight Ni 0 0.5% by weight Cr 0 0.5% by weight Zn balance.

2. The method of claim 1 wherein said soldering is carried out by means of ultrasonic soldering.

3. The method of claim 1 wherein said soldering is carried out by means of rub soldering.

4. The method of claim 1 wherein said aluminum or aluminum alloys are soldered to a metal selected from the group consisting of copper, brass, iron, stainless steel, nickel and chromium.

5. The method of claim 4 wherein the soldering operation is carried out by using a flux composition. 

2. The method of claim 1 wherein said soldering is carried out by means of ultrasonic soldering.
 3. The method of claim 1 wherein said soldering is carried out by means of rub soldering.
 4. The method of claim 1 wherein said aluminum or aluminum alloys are soldered to a metal selected from the group consisting of copper, brass, iron, stainless steel, nickel and chromium.
 5. The method of claim 4 wherein the soldering operation is carried out by using a flux composition. 